US7132172B2 - Composite material for use in the manufacture of electrical contacts and a method for its manufacture - Google Patents

Composite material for use in the manufacture of electrical contacts and a method for its manufacture Download PDF

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Publication number
US7132172B2
US7132172B2 US10/744,908 US74490803A US7132172B2 US 7132172 B2 US7132172 B2 US 7132172B2 US 74490803 A US74490803 A US 74490803A US 7132172 B2 US7132172 B2 US 7132172B2
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Prior art keywords
composite material
diameter
additive
contact
metal strip
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US20040202884A1 (en
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Isabell Buresch
Hermann Strum
Roland Binder
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Wieland Werke AG
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Wieland Werke AG
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Assigned to WIELAND-WERKE AG reassignment WIELAND-WERKE AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BINDER, ROLAND, STRUM, HERMANN, BURESCH, ISABELL
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C22C1/1042—Alloys containing non-metals starting from a melt by atomising
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • C23C28/023—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material only coatings of metal elements only
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/123—Spraying molten metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0832—Handling of atomising fluid, e.g. heating, cooling, cleaning, recirculating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0892—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid casting nozzle; controlling metal stream in or after the casting nozzle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C2204/00—End product comprising different layers, coatings or parts of cermet
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H1/00—Contacts
    • H01H1/02—Contacts characterised by the material thereof
    • H01H1/021—Composite material
    • H01H1/023—Composite material having a noble metal as the basic material
    • H01H1/0237—Composite material having a noble metal as the basic material and containing oxides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H1/00—Contacts
    • H01H1/02—Contacts characterised by the material thereof
    • H01H1/021—Composite material
    • H01H1/027—Composite material containing carbon particles or fibres
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2300/00—Orthogonal indexing scheme relating to electric switches, relays, selectors or emergency protective devices covered by H01H
    • H01H2300/036—Application nanoparticles, e.g. nanotubes, integrated in switch components, e.g. contacts, the switch itself being clearly of a different scale, e.g. greater than nanoscale
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12014—All metal or with adjacent metals having metal particles
    • Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063—Nonparticulate metal component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12014—All metal or with adjacent metals having metal particles
    • Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063—Nonparticulate metal component
    • Y10T428/12069—Plural nonparticulate metal components
    • Y10T428/12076—Next to each other
    • Y10T428/12083—Nonmetal in particulate component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12014—All metal or with adjacent metals having metal particles
    • Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063—Nonparticulate metal component
    • Y10T428/12104—Particles discontinuous
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12014—All metal or with adjacent metals having metal particles
    • Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063—Nonparticulate metal component
    • Y10T428/12139—Nonmetal particles in particulate component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12708—Sn-base component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12861—Group VIII or IB metal-base component
    • Y10T428/12896—Ag-base component

Definitions

  • the invention relates to an electrically conductive composite material for use in the manufacture of electrical contact components consisting of a metal strip and a contact layer made of a silver or tin contact material, which contact layer is applied at least to one side of the metal strip. Moreover a device is provided for the gas atomization of a jet of flowable or liquid material and a method for the manufacture of an electrically conductive composite material.
  • Such electrical contact components are utilized, for example, as plug contacts in plug connectors or in plug-connector connections in the automotive industry.
  • the design of the contact elements is of great importance for the reliability of plug connectors.
  • the utilized contact carrier material together with the utilized contact surface determines during operation the aging behavior and the lifetime characteristics.
  • the known electrical contacts for this use consist usually of a base body (metal strip), in particular made of a Cu alloy, and a contact material applied galvanically, via hot dip tinning or via cladding. In particular gold, silver or tin layers are used for this purpose.
  • a powder-metallurgical manufacture of the contact points, which are welded onto the contact area, is not possible for plug connectors, in particular the female part, since the contact area is being reshaped and thus is not freely accessible.
  • a material for electrical contacts made of silver and carbon is known from the reference DE 195 03 184 Cl.
  • This reference deals with a sintered material, which due to a certain carbon-black content has an improved burning characteristic.
  • the carbon is for its manufacture added in the form of carbon black with a primary particle size of less than 150 nm to silver, the mixture is isostatically cold pressed and thereafter sintered.
  • a composite material for electrical contacts is known from the reference DE 41 11 683 C2.
  • the composite material consists of silver or a silver alloy with a carbon content, which is processed in the form of a combination of a carbon powder and carbon fibers in a mass ratio of 10:1 to 1:10 with the metal component.
  • a device with an atomizer is known from the reference EP 0 225 080 B1, with which device a jet of a liquid metal is atomized with a gas jet into a spray mist consisting of droplets.
  • the atomizer is thereby supported tiltably about a stationary axis in such a manner that the spray mist is evenly distributed on a moving band-shaped substrate or another collecting device.
  • the device is used for the manufacture of thin metal strips or for coating of strips.
  • a surface-like even distribution of the applied metal layer is indeed achieved with this manufacturing method, however, it permits first of all only a simple material selection with one melt component. Furthermore an atomizer movable relative to the metal jet represents an additional apparatus expenditure.
  • the basic purpose of the invention is therefore to provide a metallic composite material, which is manufactured by means of a device, which is improved compared with the state of the art, and which also meets the increased demands mentioned above.
  • the composite material of the invention is suited in particular for plug connectors and plug-connector connections and also switching contacts.
  • the invention is thereby based on the premise that the composite material should have a plurality of characteristics which are optimally adjusted to one another.
  • the composite material should have a plurality of characteristics which are optimally adjusted to one another.
  • the arc erosion resistance for use in 42 V electrical systems in the automotive field should thereby be the main topic in order to prevent a burning away of the contacts.
  • the electrically conductive composite material is for this purpose provided with an additive of carbon.
  • the electric arc created during the plugging in and pulling out of plug connectors and contacts produces carbon compounds, through which an increase of the contact resistance through oxidation of the contact surfaces in the surrounding area is essentially prevented.
  • the main portion of the contact layer is a metal having an already good electrical conductivity, which forms the matrix into which the two additives are embedded and finely distributed corresponding to their small diameter to form a homogeneous composite material.
  • This has also a direct positive effect on further material characteristics.
  • the finely distributed alloy components of varying hardness and the therewith achieved homogenization opposes the wear of a mechanically stressed surface.
  • Carbon has a decidedly low hardness in comparison to metallic materials. Especially for this reason it is of importance that the small particle size of this additive in the nanometer range leads to a composite material which has on its surface, due to metallic parts, a sufficient hardness and thus abrasion resistance against mechanical stress.
  • the soft carbon powder is for this purpose embedded in a harder metallic skeletal matrix.
  • the second additive considers materials which improve the electrical conductivity, arc-erosion resistance, hardness and abrasion resistance. Thus also metallic particles can be introduced.
  • hard particles can also be considered as the second additive.
  • the metal strip consists advantageously of Cu or a Cu alloy, of Fe or a Fe alloy, of Al or an Al alloy, of Ni or a Ni alloy.
  • the advantages achieved with the invention are, with respect to the composite material in particular, the composite material, at high plug-in and pull-out speeds, either prevents the creation of an electric arc or if an electric arc is created, it is immediately extinguished so that oxidation of the contact surface will not result.
  • the intermediate layer guarantees an optimum adhesiveness of the contact layer on the base material.
  • the inventive solution optimizes the characteristics of the composite material for use in electrical engineering techniques.
  • the device for the gas atomization of a jet of a flowable or liquid material for example a jet of liquid metal or a metal alloy
  • an atomizing system for the admission of atomizing gas onto the jet for the atomization of the jet into a spray mist consisting of droplets, whereby the atomizing system.
  • the atomizing system is constructed annularly or elongated, and has a continuous outlet gap for the atomizing gas.
  • an injector for powder with a swirling chamber which injector is connected to a solid material feed system.
  • the advantages achieved with the invention are, with respect to the device for the gas atomization, that powder parts in the swirling chamber are homogeneously moved into the spray mist.
  • the high gas speed of the atomizing gas produces for this purpose in the area of the swirling chamber an underpressure which continuously effects a discharging of the powder particles from the chamber.
  • the particle movement in the swirling chamber dissolves the agglomeration of fine powder particles and thus takes care of a homogeneous distribution in the separated layer. It is in particular possible to coat wider strips having an elongated form of the atomizing system without the gas-atomizing device or its parts being moved.
  • the elongated part is for this purpose aligned perpendicularly with respect to the direction of movement of the strip material.
  • the solid material feed system includes in a preferred embodiment a storage container for dry powder or a container for liquids loaded with powder with supply lines.
  • the amount of material in the jet is advantageously controlled by a device having valve control and/or a device for the pressurization of a melt storage container.
  • a device having valve control and/or a device for the pressurization of a melt storage container With a suitable pressurization it is possible to specifically control the material flow even without a valve since a melt flow can only be maintained with a suitable overpressure.
  • An additional valve permits yet shorter switching times to switch on and off the melt flow.
  • the purpose is attained, with respect to the method for the manufacture of a composite material with a device for the gas atomization, with the steps according to which a metal or a metal alloy is heated in a storage container above the melting point, the melt exists with pressurization in the form of a melt jet and is atomized by means of a flow of gas into a spray mist, is mixed with non-melting additives in particle form, and subsequently the atomized droplets are deposited on a metal strip as a carrier material or a collecting device.
  • a cooling conveyor moving under the spray jet can serve as the collecting device, from which cooling conveyor the spray product can be released.
  • the non-melting additives are fed in a preferred embodiment to the melt flow from a swirling chamber.
  • This manufacturing method can work either in a continuous operation or in a batch operation, where the strip to be coated is supplied either continuously or from a stack of superposed strip sections.
  • the system is stored in a housing with an inlet and outlet lock, which housing is flooded with nitrogen or a nitrogen/hydrogen mixture.
  • a strip-cleaning and strip-activating station is positioned in front of the inlet lock, with which station the strip surface is suitably prepared prior to the coating for a good adhesiveness of the deposited layer.
  • the atomization of the powder particles occurs in a preferred embodiment by using N 2 .
  • the additives are for this purpose blown into the spray jet with a pressure of 0.15 to 1.5 MPa.
  • the nitrogen enters due to the overpressure with a very high pressure through an outlet gap into a mixing chamber in order to swirl around the powder particles introduced into the mixing chamber and to obtain an optimum thoroughly blended mixture.
  • the pressurization of the powder components is for this purpose suitably controlled for an optimum blending.
  • the additives are advantageously blown independently from one another.
  • the metal strip is for this purpose advantageously heated to a temperature of (0.6 to 0.9) ⁇ T s of the contact material Sn or Ag.
  • the metal strip is, prior to the depositing of the layer, advantageously surface-treated with a fluxing agent for activation.
  • the layer thickness is adjusted through still other depositing parameters.
  • the thickness D 2 of the contact layer is in a preferred embodiment for this purpose controlled by the spray jet density and the running speed of the metal strip to be coated.
  • the spray jet density is preferably controlled by a needle valve or something similar. When the needle valve is thereby permanently open, then it is also possible for an all-over one-sided coating to occur. To create a uniform layer the metal strip can be pulled through under the spray jet at a constant speed. As an alternative, it is also possible to control alone without the valve device through a pressurization of the melt the material flow in the spray head.
  • the depositing conditions it is possible to also specifically adjust the porosity of the contact layer.
  • An open porosity of the contact layer of 70 to 85% is adjusted in a particularly advantageous embodiment through the chosen spray parameters.
  • the porous contact layer is subsequently infiltrated with oil for self-lubrication.
  • Porous layers are aftertreated in a further method step by re-rolling the sprayed metal strip at a temperature of at least 0.8 ⁇ T s of the layer matrix material in order to achieve a 100% thickness.
  • the metal strip is in a particularly preferred embodiment only partially coated.
  • a partially resistive coating for example, at the tip of a connector.
  • the metal strip is advantageously covered with a mask.
  • a mask is for this purpose not placed onto the carrier but is positioned at a certain distance in the jet.
  • the advantages achieved with the invention consist, with respect to the method in particular, in the contact coating of a metal strip being partially applied as a carrier material in order to manufacture automatically switching-off contacts with little burning away behavior.
  • a contact layer is produced on a carrier material during one operating sequence through a suitable parameter selection, which contact layer can be further processed directly as strip material. Beyond already existing manufacturing methods it is thus possible to include the coating process easily in a rational series production.
  • FIG. 1 illustrates a composite material having a carrier and a contact layer
  • FIG. 2 is a schematic illustration of the gas-atomizing device.
  • the composite material 1 for the manufacture of electrical contact components consists of a metal strip 2 as the carrier made of metal and a contact layer 4 made of a silver or tin contact material, which contact layer is applied at least to one side thereof.
  • the metal strip 2 is surface-treated with a fluxing agent for activation.
  • the gas-atomizing device 10 schematically illustrated in FIG. 2 houses a melt container 12 , which is arranged in a heated housing 40 and has filler necks and feed channels 14 for feeding the melt to a nozzle 28 .
  • a needle valve mechanism 18 is provided from which the jet of liquid metal or a metal alloy exits. The exiting amount is controlled by a connection 16 which subjects the chamber 12 to pressurization, which connection is mounted on the melt container 12 .
  • the filler neck on the melt container 12 to facilitate a pressurization thereof, is closed off gastight with a plug or a screw connection.
  • a container 20 is in addition arranged in the heated housing 40 , which container has filler necks for liquids and mixtures made of a liquid loaded with powder.
  • the container 20 is connected via feed channels 22 to the injector system 32 having a swirling chamber 26 , which injector system 32 encircles the needle valve 18 .
  • the exiting amount from the container 20 is also controlled by a connection 24 mounted on the container 20 to subject the chamber 20 to pressurization.
  • further solid material feed systems having a powder receptacle 44 for dry powder to the heated housing 40 , which systems are connected to the injector system 32 via channels not shown in the schematic illustration. Further melt receptacles, if necessary with a separate heating system, can be docked to a connecting system 42 .
  • the melt exiting through the needle valve 18 is mixed with the solid materials from the swirling chamber 26 and is loaded with atomizing gas from a N 2 atomizing system 34 so that from the jet is created a spray mist consisting of droplets, which spray mist is deposited on a strip 2 .
  • a N 2 chamber 36 directly in front of the N 2 outlet gap 38 , assures a constant gas supply.
  • a mask 8 is positioned in the path of the jet spray or on the substrate to facilitate a selective depositing.
  • the atomizing system 34 can be of an annular configuration or elongated into the image plane of FIG. 2 , whereby same has a continuous outlet gap 38 for the N 2 atomizing gas.
  • the metal strip 2 is pretreated on the surfaces with flow medium for activation by the cleaning and activating system 48 .
  • the strip can be coated in a continuous operation or in the form of a stacked array 46 in a batch operation.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Powder Metallurgy (AREA)
  • Contacts (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Manufacture Of Switches (AREA)
  • Conductive Materials (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
US10/744,908 2002-12-27 2003-12-23 Composite material for use in the manufacture of electrical contacts and a method for its manufacture Expired - Fee Related US7132172B2 (en)

Applications Claiming Priority (2)

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DE10261303A DE10261303B3 (de) 2002-12-27 2002-12-27 Verbundmaterial zur Herstellung elektrischer Kontakte und Verfahren zu dessen Herstellung
DE10261303.6 2002-12-27

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JP (1) JP4571397B2 (ja)
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US20060148339A1 (en) * 2003-04-17 2006-07-06 Franz Kaspar Electrical plug contacts and a semi-finished product for the production thereof
US20080203063A1 (en) * 2005-09-13 2008-08-28 Abb Technology Ag Vacuum interrupter chamber
US20100041284A1 (en) * 2007-01-24 2010-02-18 Martin Beck Base for an electric lamp
US11456123B2 (en) 2018-02-27 2022-09-27 Tdk Electronics Ag Switching device

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US20060148339A1 (en) * 2003-04-17 2006-07-06 Franz Kaspar Electrical plug contacts and a semi-finished product for the production thereof
US20060068220A1 (en) * 2004-09-29 2006-03-30 Dowa Mining Co., Ltd. Tin-plated product
US7651785B2 (en) * 2004-09-29 2010-01-26 Dowa Mining Co., Ltd. Tin-plated product
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US7939777B2 (en) * 2005-09-13 2011-05-10 Abb Technology Ag Vacuum interrupter chamber
US20100041284A1 (en) * 2007-01-24 2010-02-18 Martin Beck Base for an electric lamp
US11456123B2 (en) 2018-02-27 2022-09-27 Tdk Electronics Ag Switching device

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KR20040060753A (ko) 2004-07-06
DE50312017D1 (de) 2009-11-26
CN1519991A (zh) 2004-08-11
CN1519991B (zh) 2011-05-18
DE10261303B3 (de) 2004-06-24
ATE445719T1 (de) 2009-10-15
KR101090190B1 (ko) 2011-12-06
US20040202884A1 (en) 2004-10-14
EP1433867B1 (de) 2009-10-14
EP1433867A3 (de) 2006-05-17
JP4571397B2 (ja) 2010-10-27
EP1433867A2 (de) 2004-06-30
JP2004214183A (ja) 2004-07-29

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